Assembly

1. Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2. Install case assembly in carrier.
3. Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.





4. Align match marks on cap and carrier. Screw in two side bearing cap bolts two or three turns and press down bearing cap by hand.
Provisional Tightening Torque (a) 15 Nm (11.0 ft. lbs.)

NOTE: If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.





5. Tighten both bearing adjusters so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.
Bevel gear backlash: 0.13-0.18 mm (0.005-0.007 inch)
Special Tools:
(A) 09930-40120 (Attachment)
(B) 09930-40113 (Rotor holder)

NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- As a practical measure, the following would be recommended to obtain specified backlash and side bearing preload at the same time.
1. Obtain specified backlash by turning both adjusters inward lightly.
2. Tighten both adjusters further by one notch at a time.





6. Measure preload of pinion with Special Tool (E) 09922-75222 (spring balance or torque wrench) and check composite preload of pinion bearing and side bearing.

Example: When preload of bevel pinion is 2.6 kg (5.73 lbs.), acceptable composite preload of both pinion bearings and side bearings should be between 2.8-3.2 kg (6.17-7.05 lbs.)





NOTE: Standard preload is shown in graph, which should be read as follows:





- Bearing preload can be checked roughly by using Special Tool (F) 09922-66020 (flange holder) as shown in the figure. In this measurement, holder arm itself will work as balance weight and torque will be replaced with angle. However, flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia.
- Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification, if fail to obtain specified measurements first.





7. Torque bearing cap bolts to (a) 85 Nm (61.5 ft. lbs.) and install bearing lock plates. tighten lock plates to (b) 12 Nm (108 inch lbs.)





8. Install rear wheel sensor, if equipped.





9. As final step, check gear tooth contact as follows.
1. After cleaning tooth surface of 10 bevel gears, paint them with gear marking compound evenly by using brush or sponge etc.
2. Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact.





3. Bring painted part up and check contact pattern, referring to the chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.

NOTE: Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.





10. Upon completion of gear tooth contact check in step 8, caulk flange nut with caulking tool and hammer.